Order Picking Warehouse Flow for Mixed B2B and B2C Packaging

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Solution Overview

Problem

Existing order picking warehouses struggle to efficiently handle diverse article orders from both e-commerce (B2C) and retail (B2B) without incurring high transport volumes and repeated article manipulations, particularly when processing orders with varying package formats and quantities.

Innovation Solution

An improved method and warehouse design that allows for order-oriented unloading of articles directly into shipping packages or collective loading aids at the unloading station, followed by automated conveyance to packaging stations for secondary packaging, optimizing handling steps and reducing disruptions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If articles are manually packed into shipping packages at packing stations after picking, then packaging flexibility is maintained, but handling effort and processing time increase

Engineering Contradiction:

Improvepackaging flexibilityVSAvoidhandling effort

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system segments the order fulfillment process into two distinct paths: a first picking order path where articles are transferred directly into shipping packages at the unloading station, and a second picking order path where articles are transferred into collective loading aids first and then into shipping packages at packaging stations. This segmentation allows different handling approaches for different order types, reducing overall handling effort while maintaining packaging flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by pre-positioning shipping packages at the unloading station for first picking orders, enabling direct transfer of articles from transport loading aids into the final shipping packages without intermediate handling. This preliminary preparation eliminates subsequent repacking operations and reduces total handling effort.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If articles are transferred directly into shipping packages at the unloading station, then handling steps are reduced, but package format adaptability decreases

Engineering Contradiction:

Improvehandling stepsVSAvoidpackage format adaptability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system divides order processing into two streams: first picking orders that benefit from direct transfer into pre-positioned shipping packages at the unloading station, and second picking orders that require transfer into collective loading aids first and then into shipping packages at packaging stations. This segmentation ensures that direct transfer is applied only where appropriate while maintaining adaptability for other order types.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically selects the processing path based on order characteristics. For first picking orders with suitable package formats, the system enables direct transfer to shipping packages. For second picking orders requiring different package formats or consolidation, the system routes articles through collective loading aids to packaging stations. This dynamic adaptation maintains versatility while optimizing handling efficiency.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If multiple transport loading aids are unloaded sequentially into shipping packages, then article sorting precision improves, but processing time increases

Engineering Contradiction:

Improvearticle sorting precisionVSAvoidprocessing time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary actions by pre-positioning the required shipping package at the unloading station before the transport loading aids arrive. This allows articles to be transferred directly into the final destination package in a single operation, eliminating subsequent repacking steps and reducing total processing time while maintaining sorting precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system extracts the shipping package from the subsequent packaging process and positions it in advance at the unloading station. This extraction allows the unloading operation to complete the entire transfer process in one step, rather than performing partial transfers followed by consolidation operations, thereby reducing processing time without compromising sorting accuracy.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20260004239A1Method and picking warehouse for picking goods of different picking orders

Publication Date: 2026.01.01 TGW LOGISTICS GMBH

AI summary

A method and an order picking warehouse is for picking and packaging articles. The order picking warehouse comprises an order management system, transport loading aids, an automatic unloading station, a provisioning device for providing a shipping package or a collective loading aid at the unloading station and a packaging station. Picking orders are acquired and the articles are provided in transport loading aids and transported to the unloading station. At the unloading station, optionally a shipping package or a collective loading aid, into which the articles are reloaded from the transport loading aids, is provided on the basis of the picking order. The filled shipping package can be transported away and shipped to an article recipient. The filled collective loading aid, however, is provided at the packaging station, where the articles are reloaded from the collective loading aid into a secondary package.